Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/04—Construction or manufacture in general
  • H01M10/0413—Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/04—Construction or manufacture in general
  • H01M10/0436—Small-sized flat cells or batteries for portable equipment
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/04—Processes of manufacture in general
  • H01M4/0402—Methods of deposition of the material
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/04—Processes of manufacture in general
  • H01M4/0402—Methods of deposition of the material
  • H01M4/0421—Methods of deposition of the material involving vapour deposition
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/36—Selection of substances as active materials, active masses, active liquids
  • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
  • H01M4/483—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides for non-aqueous cells
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/36—Selection of substances as active materials, active masses, active liquids
  • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
  • H01M4/485—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/36—Selection of substances as active materials, active masses, active liquids
  • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
  • H01M4/5825—Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M6/00—Primary cells; Manufacture thereof
  • H01M6/40—Printed batteries, e.g. thin film batteries
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/052—Li-accumulators
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/058—Construction or manufacture
  • H01M10/0585—Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M2004/021—Physical characteristics, e.g. porosity, surface area
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M2220/00—Batteries for particular applications
  • H01M2220/10—Batteries in stationary systems, e.g. emergency power source in plant
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M2220/00—Batteries for particular applications
  • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M2220/00—Batteries for particular applications
  • H01M2220/30—Batteries in portable systems, e.g. mobile phone, laptop
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M2300/00—Electrolytes
  • H01M2300/0017—Non-aqueous electrolytes
  • H01M2300/0065—Solid electrolytes
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
  • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

• the thin film energy storage device, and all solid-state devices that the method of present invention can apply to, can be used for a variety of applications such as a solar panel, a consumer electronic device, a vehicle, or an electrical grid;
• the consumer electronic devices include, but not limited to: display device, MP3 players, smartphones, tablets, laptop computers, smartwatches, activity trackers, and other wearable devices;
• the vehicles include, but not limited to: hybrid electric buses, electric buses, hybrid electric cars, electric cars, electric bicycles, electric motorcycles, electric scooters, electric golf carts, trains, ships, airplanes, electric airplanes, helicopters, unmanned aerial vehicles, electric unmanned aerial vehicles, drones, other aerial vehicles, space stations, space shuttles, space planes, satellites, unmanned spacecrafts, other spacecrafts, and other hybrid electric vehicles, plug-in hybrid electric vehicles, and electric vehicles; and wherein the electrical grid includes, but not limited to stand-alone micro-grids for residential homes, commercial buildings, and communities, and centralized electrical grids.
• the substrate member can include a surface region and can be characterized by a melting point temperature.
• the barrier material can be formed overlying the surface region of the substrate member.
• This barrier material can include a polymer material and can be configured to substantially block a migration of an active metal species to the substrate member.
• the barrier material can be characterized by a barrier degrading temperature.
• the first electrode material can be formed overlying the surface region as well.
• the thickness of cathode material can have an amorphous characteristic.
• the formation of this cathode material can be executed while maintaining a temperature ranging from about -40 Degrees Celsius to no greater than 500 Degrees Celsius.
• the formation of the cathode material can be such that a spatial volume is characterized by an external border region of the cathode material, the thickness of cathode material is characterized by an effective diffusivity having a value ranging from l .E-18 m 2 /s to l .E-4 m 2 /s, and the cathode material is characterized by a void region being 0.001% to 80% of the spatial volume.
• the cathode material includes a lithium species, the lithium species being selected from at least one of LiSON, Li x Lai_ x Zr0 3 , Li x Lai_ x Ti0 3 , LiAlGeP0 4 , LiAlTiP0 4 , LiSiCON, Lii. 3 Alo. 3 Tii. 7 (P0 4 ) 3 , 0.5LiTaO 3+0 . 5 SrTiO 3 , Lio.
• LiSON Li x Lai_ x Zr0 3
• Li x Lai_ x Ti0 3 LiAlGeP0 4
• LiAlTiP0 4 LiSiCON, Lii. 3 Alo. 3 Tii. 7 (P0 4 ) 3 , 0.5LiTaO 3+0 . 5 SrTiO 3 , Lio.
• the present invention provides a suitable solid state battery structure including barrier regions.
• the cathode material is configured to provide improved power density for electrochemical cells.
• the present cathode material can be made using conventional process technology techniques. Of course, there can be other variations, modifications, and alternatives.
• FIGURE 2C is a microscopic graph view of the same area as the schematic drawing shown in FIGURE 2A according to an embodiment of present invention.
• FIGURE 2F is a scanning electron microscope graph of the "bridge" region shown in FIGURE 2C according to an embodiment of present invention.
• FIGURES 4A - 4F illustrate simplified cross-sectional views of each process step showing an electrochemical cell layer formed according to an embodiment of the present invention.
• FIGURE 7 is a simplified cross-sectional view of an illustration of a cathode material according to an embodiment of the present invention.
• FIGURE 8 is a simplified cross-sectional view of an illustration of a cathode material according to an embodiment of the present invention.
• FIGURES 20-22 are values based upon experimental results according to examples of the present invention.
• present invention provides a method for fabricating a thin film electrochemical energy storage device or an all solid-state device to achieve better performance and longer cycle lifetime by using multiple active and intermediate thin film layers serving either as stress mitigation means, thermal control means, ionic diffusion prevention means, ionic diffusion enhancing means, enhancing electrical conduction means, electrical insulation means, adhesion means, or the most importantly planarizing means for subsequent layers.
• the performance of those devices can either be electrical-chemical conversion efficiency, photovoltaic conversion efficiency, electrical conduction, electrical insulation, or high/low temperature operational capabilities.
• the materials used to form intermediary thin- film planarizing layers overlying the flaws of electrochemical/electrical active layer(s) within a thin film energy storage device or other solid-state device having inert physical properties can be categorized into four groups, but not limited to, based on their functions:
• the materials used to form intermediary one or more thin film planarizing layers overlying the first electrochemical/electrical active layer(s) within a solid state battery or other solid-state thin film device having inert properties to mitigate flaws, to prevent mechanical failures due to an oxygen species, a water species, a nitrogen species, and a carbon dioxide species from diffusing into electrochemical/electrical active layers, or to prevent contamination from bonding to, alloying, mixing or forming a composite with the first layer due to the formation of this intermediated one more thin film layers.
• the selection of the materials to form this planarizing layer unit is closely depending on its intention.
• the material for this layer can be selected from a group ceramic, but not limited to, aluminum oxide, aluminum nitride, zirconium dioxide (zirconia), magnesium oxide, yttrium oxide, calcium oxide, cerium (III) oxide and boron nitride. If this planarizing layer is used also as a moisture resistance, the material for this planarizing layer can be selected, but not limited to, from a group of metals, glass, ceramics, mica, silicone resins, asbestos, acrylics, diallyl phthalate, and plastic resins.
• one or more planarizing layers are used to fills pinholes and cracks.
• the thicknesses, orders and selection of these planarizing layers depend on the flaw dimensions, and type of the materials of the proceeding layers. Furthermore, the types of microstructures of these planarizing layers can alter their own material properties. Carefully choosing the proper evaporation methods are necessary because types of evaporation methods, their background gases, and substrates, evaporation sources temperature are closely related to the end product's microstructure of the films.
• present invention provides a method utilizing one or more inert layers overlaying other layers of dissimilar materials to constrain diffusion of species or conduction of electrons, wherein the stacking sequence of said layers is either in a single stack or in repeats one or more times.
• the inert layer used to prevent diffusion of strong reactive species throughout the layers within the thin film energy storage device or an all solid- state devices.
• the strong reactive species that the inert layers try to control include, but not limited to, lithium atoms, lithium ions, protons, sodium ions, and potassium ions, or other ionic species.
• one or more thin film planarizing layers overlaying on the electrical/electrochemical active layer of a thin film energy storage device or an all solid-state device enable devices operation under high temperature, ruggedness, resistance to harsh environments including chemical and physical degradation, and providing electrical isolation.
• present invention provides a method of utilizing one or more thin film planarizing layers overlaying on the electrical/electrochemical active layer of a thin film energy storage device or an all solid-state device enable devices operation under high temperature, ruggedness, resistance to harsh environments including chemical and physical degradation, and providing electrical isolation.
• several thin-film layers sequentially are deposited on top each other to form functional unit, and their orders are:
• the adhesive layer has total thickness less than 500 Angstroms, and the materials of this adhesive layer are selected from either: a group of elastomers, such as butyl, styrene butadiene, phenolic, polysulfide, silicone, or neoprene; a group of polymer electrolyte, such as metal salts, AX (where A + is anodic ion and is selected from a group of metals, but not limited to, Li + , Na + , Mg 2+ , etc., and X “ is cathodic ions, but are not limited to, T, CI " , Br “ , CIO 4 " , CF 3 SO 3 " ,BF 4 " , and AsF 6 " ), in polymer where polymer is chosen from a group of polymer such as, poly(ethylene oxide) (PEO), poly(propylene oxide) (PPO), poly(ethylene glycol) (PEG), poly(vinylidene fluoride) (PEO),
• the types of materials that can be used to insulating temperature can be selected either from a group of ceramic, such as soda-lime, mica, and borosilicate; from a group of metal, such as aluminum, silver copper, zinc, indium, and tin; or from a group of polymer, such as ethylene (E), polyethylene, propylene (P), vinyl fluoride, vinylidene fluoride, tetrafluoroethylene, hexafluoropropylene, perfluoropropylvinylether, perfluoromethylvinylether, chlorotrifluoroethylene, polycarbonate, polyetherimide (PEI), polymide, polystyrene, epoxy, and phenolic materials.
• a group of ceramic such as soda-lime, mica, and borosilicate
• metal such as aluminum, silver copper, zinc, indium, and tin
• polymer such as ethylene (E), polyethylene, propylene (P), vinyl fluoride, vinylidene flu
• present invention provides a method of using plurality of bi-layers in a thin film electrochemical system or other solid-state devices to prevent diffusion of Li or other active species from the solid-state device and to protect thin film electrochemical system or solid-state device from service environments that can react with the active materials such as oxygen, moisture or nitrogen.
• the first layer is a polymer layer, which is inert and will not react with the active material. This polymer layer has two functions: preventing diffusion of the active material ionic species, and serving as planarizing layer for subsequent layer.
• the second layer of this bi-layered functional unit is comprised of inorganic materials.
• FIGURE IB is a simplified cross-sectional view of a modified thin film electrochemical cell, 102, with an additional diffusion barrier layer over the bridge region between the electrolyte and the anode layers according to an embodiment of present invention.
• FIGURE IB illustrates a cross-sectional view of a modified electrochemical cell with an additional diffusion barrier layer 170 over the bridge region between the electrolyte and the anode layers to prevent anode species (i.e. lithium ion) from diffusing into the substrate or other under layer materials.
• anode species i.e. lithium ion
• FIGURES 4A - 4F illustrate simplified cross-sectional views of each process step showing an electrochemical cell layer formed according to an embodiment of the present invention.
• a substrate is provided in FIGURE 4A.
• the anode and the cathode current collectors ACC and CCC
• ACC and CCC are deposited on the substrate
• cathode material is deposited on the cathode current collector (FIGURE 4C)
• the material of the electrolyte is deposited over the cathode (FIGURE 4D)
• the diffusion barrier is deposited over the bridge region across the electrolyte between the active area where the cathode material is deposited and the anode current collector (FIGURE 4E)
• anode material is deposited over the active area, the bridge region, and a portion of the anode current collector (FIGURE 4F).
• the electrolyte can be configured overlying the cathode material.
• the thickness of cathode material can include a first thickness of amorphous material and a second thickness of material.
• the first thickness of cathode material can be greater than the second thickness, and the first thickness of amorphous material can be different in structure than the second thickness of material.
• the cathode material can also include a surface morphology.
• the effective diffusivity includes a first diffusivity of the first thickness and a second diffusivity of the second thickness.
• the cathode material can be characterized by a conductivity ranging from l .E-12 S/m to 1.E4 S/m, by a C rate ranging from C/100 to lOOC, by an XRD peak to total ratio ranging from 0% to 50% crystallinity, and by an average crystallite size ranging from 0.1 nm to lOOnm configured in a spatial region.
• FIGURE 8 is a simplified cross-sectional view of an illustration of a cathode material 800 according to an embodiment of the present invention.
• the formation of the cathode material can include forming a plurality of first cone structures 811 and a plurality of second cone structures 812 such that the plurality of first cone structures 811 is inter-digitated with the plurality of the second cone structures 812.
• Figure 22 shows a graph of the related data for the second sample.
• This cell sample was provided on a glass substrate.
• the dimensions for this cell sample were as follows: current collector (CC): 0.1 lum, cathode (CA) 1.09um, electrode (EL): 0.49um, and anode (AN): 0.9um.

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• 2014
  • 2014-10-15 US US14/514,779 patent/US9627709B2/en active Active
• 2015
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